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Don’t Be Caught Off Guard
Fire Response Lessons Learned From Underground Mines
BY RONALD CONTI, LINDA CHASKO, WILLIAM WIEHAGEN AND CHARLES LAZZARA

Despite a disastrous January for West Virginia coal miners, there has been significant progress over the years in reducing the number of lives lost to mine fires.

Though 12 miners died in the Sago Mine Explosion Jan. 2, today, there is a better scientific understanding of fire risk within the mining community and ways to minimize risk when fire does occur.

This is mostly attributed to improved fire-resistant materials, better detection systems, fire suppression systems, and a more skilled workforce. Research conducted over a long period has led to better standards of acceptable performance. At the same time, due to the nature and characteristics
of mining, fire is a constant threat. Small fires have occurred and always will occur in underground
mines.

There is no accurate record of small mine fires. However, some fires are required to be reported. Statistics maintained by the Mine Safety and Health Administration (MSHA) indicate that 137
underground coal, metal and nonmetal mine fires were reported in the United States during 1991–2000.

The fires resulted in two fatalities and 34 injuries (these statistics include the Willow Creek Mine explosion and fire, which accounted for two fatalities and eight injuries). Mine operators are required
to report to MSHA any unplanned mine fire that is not extinguished within 30 minutes of discovery,
or any fire, regardless of its duration, that causes an injury or fatality.

There are different levels of reporting across companies; the only constant is those fires that are required to be reported to MSHA. For example, some mines track small fires by the number of
fire extinguishers used; others track them through production downtime reports. Some mines require internal incident reports for all unplanned fires. For planned fires, many mines require “hot work permits” when flame cutting and welding underground.

Friction is the most common cause of underground coal mine fires, while mobile equipment malfunction is the leading cause of fires in underground metal/nonmetal mines.

Fire is a common concern for underground workers. In 1998, a fire occurred during production at Cyprus Plateau Mining Corp.’s Willow Creek underground coal mine near Price, UT. All underground
miners evacuated with no serious injuries. The mine was sealed and inert gas injected into the fire area.

The mine returned to normal operations about a year later. Nine months later, two miners died
and eight were injured because of a series of four explosions and fire. Another fire occurred on Feb. 8, 2001, at the Homestake Gold Mine, Lead, SD.

Thirty-seven miners evacuated. Rescue teams mustered and discovered the fire in an old timber stope (inactive area) between the 3,500- and 3,652-ft levels.

Water was used to flood the affected area. These and other examples suggest that the remote nature of underground mining requires on-site workers to be well trained and prepared, especially in the early stages of emergency response. The early stage is critical. Decisions and actions greatly influence the outcome.

When fire does occur, escape is often complicated and may not always be a viable option. Thus, the concept of fire preparedness for the individual mine siteis an ongoing process.

Fire preparedness is a subset of emergency preparedness and has logical components of both prevention and response.

Methods to measure aspects of fire prevention and response are complex and difficult to quantify. In an emergency, it is commonplace for those involved to get the system back to normal—in minimal
time. Being prepared minimizes the negative consequences (social and economic costs) of getting the system back in balance.

It takes less time when workers are skilled in their response and have access to adequate technology. Being prepared can reduce, but not eliminate, the probability of negative consequences.
With little preparation for emergency response, higher risks for severe and long-term consequences are probable.

Negative consequences are not always limited to the specific organization and employees affected. In a serious emergency when lives are at risk, consequences (e.g., new regulations) can affect
the entire industry. Likewise, when prepared, the unexpected event offers a good opportunity for organizational learning not only within the site, but also across sites—if the information is accurately and objectively shared.

For example, when a small fire is extinguished, it can help individuals and the organization learn about their emergency response capability. In effect, it is a test of the emergency response system. Small
fires are likely at any worksite, and in one context, what is learned from those small fires can help prevent larger, more serious fires. It depends on the analysis and how one perceives and acts on the
opportunities. There are some tools available to help assess and enhance levels of fire preparedness, such as an underground coal mine fire preparedness and response checklist.

Emergency Plan
The first few minutes after discovery of a fire are crucial. The key is to minimize the time it takes to respond. Because most mine fire emergencies are unique, an emergency plan for every situation is not possible. However, there are certain elements common to all emergency plans and preparing a written plan can help reduce the turmoil associated with the emergency.

One of the most important elements of an emergency plan is a communication protocol that includes notification of key officials—and especially responders—immediately after discovery of an emergency. A competent person onsite is key. Competence implies skills— both training and experience.

Communication, protocol, and leadership skills can be taught, and assessing those skills occurs either through simulated practice or real events. Mine emergency plans that are well thought out contain many other provisions, including the surface organization, facilities and outside sources of assistance for support purposes.

At times, having access to outside experts is key, as advice from these experts can be weighed to help save time and limit the consequences. Good sources of planning for mine emergency response
can be found in Title 30 CFR and at several Web sites. In addition, the National Mine Rescue Association (NMRA) offers information on the mine emergency command structure.

The mine emergency plan should be periodically reviewed and understood. Everyone should be kept informed of any changes as modifications to the plan are made. Fire drills are an important
part of the plan and are required at 90 day intervals or more frequently. The main purpose of the drill is to test certain aspects of the emergency plan.

Organizations need to be reasonably sure that there is a balance between the technology to prevent, detect and respond to fire and the skills within the workforce to use the technology. Fire drills, in a sense, are opportunities to help workers develop or maintain skills to put the response (emergency) plan into action. Upon discovery of a mine fire, decisions are often complicated as the situation unfolds.

Fire Detection
During the incipient stages of a fire, smoke and gaseous products, including carbon monoxide (CO), are produced and released into the mine atmosphere. If these products are not detected in the early stages of combustion, they can result in severe hazards to personnel in remote and confined areas.

Many underground mine fires are discovered in their early stages by mine personnel who see or smell
smoke, then make a quick decision to both investigate and fight the fire or escape.

A review of MSHA investigative reports for underground coal mine fires that occurred during 1978–1992 and 1990–1999 found that over 75 percent of these fires were first detected by miners
who saw smoke, smelled smoke, or saw the fire start.

These findings are supported by more extensive field research detailing miners’ experiences in responding to small fires. The study detailed the experiences of workers at seven underground coal
mines to gain a better understanding of fire preparedness from 214 underground workers. Of note, only one of these mines had an MSHA reportable mine fire, yet many of the miners interviewed
(about 70 percent) indicated that, over the course of their mining career they had some direct experience in helping to extinguish a fire.

The large majority of those incipient fire incidents were first detected by miners who saw or smelled smoke. The presence of smoke underground is not unusual, as “hot work” (flame cutting and welding operations) is common and necessary to maintain mining and haulage machinery. Seeing or smelling smoke is not necessarily evidence of an emergency.

In interviewing the 214 underground miners, most reported seeing or smelling smoke about once per week to once per month. In many cases, miners are well aware of the source of the smoke.

However, being caught off guard by the sight or smell of smoke presents a different picture. In a review of seven mine fires, about 40 percent of the workers reported being caught off guard within the past month, another 30 percent in the past three months, and about 20 percent of the interviewees reported
being caught off guard within the past six months.

The source of the smoke is important. If the source is on the working section, finding and correcting the problem can be timely, effective, and relatively straightforward. However, about one third of the 214 miners indicated that they recalled being caught off guard by smoke coming from somewhere off their
section. If miners consider the presence of smoke to be commonplace at some mines, this could lead to complacency and delayed response. FSM Excerpted from a December 2005 report
titled “Fire Response Preparedness for Underground Mines” by the National Institute of Occupational Safety and Health’s.